I had the same problem on my pygmy kit if you can believe it. I am sure it was me not the kit. But, I drilled a small 1/16th hole through the deck and hull, and ran wire through and twisted the wire (stitch and glue method) to get it into shape. Then glued the seam. After the glue dried I removed the wire and taped the seam. I tried the packing tape first but coulded get the pressure I needed.

: Hi Folks.

: I've recently discovered that my hull is too wide (or, my deck too narrow).
: That is, when I slapped the deck onto the hull, and then went to tape the
: two together, they don't match exactly. Portions of the hull are anywhere
: from 1/16 to nearly 1/4 of an inch too wide, even with pressure applied.
: So, my question is: How to rectify this? I'm guessing I either make the
: deck wider, or the hull narrower, or do a little of both. My immediate
: thought is to get some strap-clamps of some sort and use those to apply
: pressure to the hull to line things up.

: Any ideas? I've got to store this for 2-3 months as I'm in the process of
: moving, so ....

: Rick Brannan
: http://www.supakoo.com/rick/kayak